Insulating sealing element for head-of-wall joints

ABSTRACT

A sealing element for sealing a gap between a support structure and a track is disclosed. The track includes a web and legs that extend vertically from the web. An embodiment of the sealing element has an insulating strip that includes an insulating material strip and a cover layer.

This application claims the benefit of U.S. Provisional Application No. 61/972,943, filed Mar. 31, 2014, the disclosure of which is expressly incorporated by reference herein.

BACKGROUND AND SUMMARY OF THE INVENTION

The present invention deals generally with the field of firestopping or acoustical insulation, in particular firestopping for head-of-wall joints, including, possibly, intumescent components.

In the building construction trade, a head-of-wall joint/gap (also sometimes referred to as a top-of-wall joint/gap) refers to the linear junction or interface existing between a top section of a framing or wallboard wall assembly and the ceiling, where the ceiling may be a next-level floor or corrugated/fluted pan roof deck, for example. A head-of-wall assembly is comprised of and defined by the following elements of overhead structure, top of wall framing deflection system, fill, void, or cavity materials protecting any joints. Corrugated/fluted deck includes either floor or roof pan deck assemblies varying in flute size, height, and configuration. Concrete decks include post-tension slabs, poured in place concrete, and precast concrete units. Gypsum drywall ceilings are common fire rated assemblies.

Head-of-wall joints often present a serious challenge in terms of reducing or preventing the spread of smoke and fire during a building fire. In this regard and in common practice, a wall to ceiling connection of many newly constructed buildings consists essentially of metal framing assemblies. These metal framing assemblies are generally constructed from a plurality of metal framing members including studs, joints, trusses, and other metal posts and beams formed from sheet metal and frequently fabricated to have the same general cross-sectional dimensions as standard members used for similar purposes. Typical head-of-wall deflection systems include the following: “single long leg track”, which is a U-shaped track having typically longer legs, typically free floating studs, some type of bracing (CRC, flatstrap) to prevent rotation of studs; “double track”, which is a nested track configured of two U-shaped profiles, designed for screw attachment to brace stud without need for other bracing materials; “slotted track”, which is a U-shaped track having vertical slots located in the legs allowing for faster attachment thought the slots, whereas screws keep the studs in place; and “slotted clips”, which are u-shaped tracks having pre-installed slotted clips that allow for attachment of fasteners through the slots, another way to attach the studs to eliminate dislodging. Although many cross-sectional shapes are available, the primary shapes used in building construction are C-shaped studs and U-shaped tracks. These C-shaped studs and U-shaped tracks may vary in their size, which, however, are standardized. The steel track (or channel) is configured to receive steel studs between the legs of the shaped channel. A wallboard is generally attached to at least one side of the studs. The studs and wallboard are in many instances spaced apart from the ceiling a short gap distance in order to allow for ceiling deflections caused by seismic activity or moving overhead loads. Track and stud assemblies that allow for ceiling deflections are commonly referred to as dynamic head-of-wall systems. Exemplary steel stud wall constructions may be found in U.S. Pat. Nos. 4,854,096 and 4,805,364 both to Smolik, and U.S. Pat. No. 5,127,203 to Paquette. Exemplary dynamic head-of-wall systems having steel stud wall constructions may be found in U.S. Pat. No. 5,127,760 to Brady and U.S. Pat. No. 6,748,705 to Orszulak et al.

Firestops are thermal barrier materials or combinations of materials used for filling gaps and openings such as in the joints between fire-rated walls and/or floors of buildings. For example, firestops can be used in walls or floors to prevent fire and smoke from passing through the gaps or openings required for cables, pipes, ducts, or other conduits. Firestops are also used to fill joint gaps that occur between walls, between a ceiling and the head-of-wall joints.

So-called head-of-wall joints pose a number of challenges for the fireproofing industry. Walls are increasingly being made of gypsum wallboard affixed to a framework of metal studs capped by a horizontally extending track. Ceilings are increasingly being made by pouring concrete onto fluted steel. Although the distance between the horizontally extending tracks at the top of the wall is often fixed in relationship to the ceiling, the gypsum wallboards are subject to expansion and contraction due to motion of other building components, ground settling, or other causes. The joint, based on amount of deflection required, is designed and constructed to allow for vertical movement, allowing the wall to move independent of the structure, due to forces such as Live/Dead loading, thermal expansion/contraction, wind sway, or seismic movements. The head-of-wall joints allow vertical movement without damaging the wall or drywall. The drywall is the fire protection component and it's key that it's not damaged/cracked.

In order to contain the spread of smoke and fire, a fire resistant material such as, for example, mineral wool is often times stuffed into the gaps between the ceiling and wallboard (see, e.g., U.S. Pat. No. 5,913,788 to Herren). For example, mineral wool is often stuffed between a steel header track (e.g., an elongated U-shaped channel) and a corrugated steel roof deck (used in many types of steel and concrete building constructions); a fire resistant and generally elastomeric spray coating is then applied onto the exposed mineral wool to thereby form a fire resistant joint seal (see, e.g., U.S. Pat. No. 7,240,905 to Stahl). In certain situations where the ceiling to wallboard gap is relatively small, a fire resistant and elastomeric caulk is commonly applied so as to fill any small gaps. In still another approach and as disclosed in U.S. Pat. Nos. 5,471,805 and 5,755,066 both to Becker, a slidable non-combustible secondary wall member is fastened to an especially configured steel header track and immediately adjacent to the wallboard. In this configuration, the secondary wall member provides a fire barrier that is able to accommodate ceiling deflections. All of these approaches, however, are relatively labor intensive and thus expensive.

Intumescent materials have long been used to seal certain types of construction gaps such as, for example, conduit through-holes. In this regard, intumescent and fire barrier materials (often referred to as firestop materials or fire retardant materials) have been used to reduce or eliminate the passage of smoke and fire through openings between walls and floors and the openings caused by through-penetrations (i.e., an opening in a floor or wall which passes all the way through from one room to another) in buildings, such as the voids left by burning or melting cable insulation caused by a fire in a modern office building. Characteristics of fire barrier materials suitable for typical commercial fire protection use include flexibility prior to exposure to heat, the ability to insulate and/or expand, and the ability to harden in place upon exposure to fire (i.e., to char sufficiently to deter the passage of heat, smoke, flames, and/or gases). Although many such materials are available, the industry has long sought better and more effective uses of these materials and novel approaches for better fire protection, especially in the context of dynamic head-of-wall construction joints and gaps.

Thus, and although construction joints and gaps are generally sealed in some manner (e.g., mineral wool and/or elastomeric coatings; see also, U.S. Patent Application No. 2006/0137293 to Klein), there are relatively few products and methods available that effectively and efficiently seal head-of-wall construction joints and gaps to thereby significantly enhance the ability of such joints and gaps to withstand smoke and fire penetration. In particular, there are very few products and methods available that address the needs for adequate fire protection and sealing of dynamic head-of-wall systems associated with steel stud wall constructions.

Recently more advanced head-of-wall fire block arrangements have been developed based on fire block header tracks. These fire block header tracks utilize an expandable fire-resistant material, such as an intumescent material, applied along a length of the header track of a wall assembly. The intumescent material is either positioned on the web of the header track, on the legs (hereinafter also referred to as flange) of the header track or alternatively wraps around a corner of the header track, extending both along a portion of a web of the header track and a flange of the header track. The intumescent material advantageously is held in place between the web of the header track and the floor or ceiling above the wall. When exposed to a sufficient temperature, the intumescent material expands to fill gaps at the head-of-wall. The portion of the intumescent trapped between the header track and the floor or ceiling ensures that the intumescent stays in place as it expands and does not become dislodged as a result of the expansion.

With the use of such fire-resistant material, the metal tracks often require a unique construction on the exterior surface of the metal track which can have a predefined area such as a recess or the like which identifies the specific location required for placement of such an intumescent and/or acoustic layer of insulation material. In particular, as the joint moves responsive to normal expansion and contraction of the building components, the insulating tape and/or the coatings of insulating material which is attached directly to the surfaces of flanges can become dislodged from components of the head-of-wall area, that is, particularly dislodging from the surfaces of the downwardly extending side sections of the track or runner. Also these systems do not specifically address variations in the contour or profile of the ceiling or roof area which comes into direct abutment with the upper portion of the metal track. Such variations in the configuration of the building construction in this area can form gaps between the track and the adjacent roof or ceiling area which are not adequately addressed for insulation by the above described prior art systems.

One of the advantages of the element of the present invention is that it is usable with conventionally OEM metal track construction and does not require any customized design for the ceiling runner.

It is an object of the sealing element for insulating head-of-wall joints of the present invention to effectively seal between conventionally designed metal track sections and the immediately adjacent roof or ceiling area for firestopping and optionally acoustic insulating thereof.

It is an object of the sealing element for insulating head-of-wall joints of the present invention to be usable with any joints and gaps between construction elements, preferably conventional steel framing and gypsum board wall constructions.

It is an object of the sealing element for insulating head-of-wall joints of the present invention to be usable with floor or roof constructions of any conventional construction including solid concrete or a composite material installed atop a corrugated steel deck.

It is an object of the sealing element for insulating head-of-wall joints of the present invention to prevent the spread of sound, noise, fire, super-heated gases, flames and/or smoke in these areas.

It is an object of the sealing element for firestop insulating head-of-wall joints of the present invention to provide more effective insulating by providing the insulating material just before the joint between the top of the metal track and the bottom of the support structure, e.g., overhead structure in case of a ceiling, to assure sealing against cold gases and smoke before the material provides a firestop at elevated temperatures.

It is an object of the sealing element for insulating head-of-wall joints of the present invention to minimize costs and maintenance requirements.

It is an object of the sealing element for insulating head-of-wall joints of the present invention to expedite installation and minimize labor costs.

Many patents have been applied or granted for various constructions for insulating head-of-wall joints as described above such as shown in U.S. Patent Application Publication No. 2011/247281 A1 published Oct. 13, 2011 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “FIRE-RATED WALL CONSTRUCTION PRODUCT”; U.S. Patent Application Publication No. 2013/031856 A1 published Feb. 7, 2013 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “FIRE-RATED WALL CONSTRUCTION PRODUCT”; U.S. Pat. No. 8,281,552 B2 patented Oct. 9, 2012 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “EXTERIOR WALL CONSTRUCTION PRODUCT”; U.S. Patent No. 8,499,512 B2 patented Aug. 6, 2013 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “EXTERIOR WALL CONSTRUCTION PRODUCT”; U.S. Patent Application Publication No. 2013/0086859 A1 published Apr. 11, 2013 to Donald A. Pilz et al. assigned to California Expanded Metal Products Company on a “FIRE-RATED WALL AND CEILING SYSTEM”; U.S. Pat. No. 7,617,643 B2 patented Nov. 17, 2009 to Donald A. Pilz et al. assigned to California Expanded Metal Products Company on a “FIRE-RATED WALL AND CEILING SYSTEM”; U.S. Pat. No. 7,950,198 B2 patented May 31, 2011 to Donald A. Pilz et al. assigned to California Expanded Metal Products Company on a “FIRE-RATED WALL AND CEILING SYSTEM”; U.S. Pat. No. 8,087,205 B2 patented Jan. 03, 2012 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “FIRE-RATED WALL AND CEILING SYSTEM”; U.S. Pat. No. 8,322,094 B2 patented Dec. 4, 2012 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “FIRE-RATED WALL AND CEILING SYSTEM”; U.S. Pat. No. 7,752,817 B2 patented Jul. 13, 2010 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “TWO-PIECE TRACK SYSTEM”; U.S. Pat. No. 8,132,376 B2 patented Mar. 13, 2012 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “TWO-PIECE TRACK SYSTEM”; U.S. Pat. No. 8,413,394 B2 patented Apr. 9, 2013 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “TWO-PIECE TRACK SYSTEM”; U.S. Pat. No. 8,555,566 B2 patented Oct. 15, 2013 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “TWO-PIECE TRACK SYSTEM”; U.S. Patent Application Publication No. 2011/214371 A1 published Sep. 8, 2011 to James A. Klein assigned to Blazeframe Ind. Ltd. on an “OFFSET LEG FRAMING ELEMENT FOR FIRE STOP APPLICATIONS”; U.S. Pat. No. 8,468,759 B1 patented Jun. 25, 2013 to James A. Klein assigned to Blazeframe Ind. Ltd. on an “FIRE RETARDANT COVER FOR FLUTED ROOF DECK”; U.S. Patent Application Publication No. 2011/146180 A1 published Jun. 23, 2011 to James A. Klein assigned to Blazeframe Ind. Ltd. on an “ACOUSTICAL AND FIRESTOP RATED TRACK FOR WALL ASSEMBLIES HAVING RESILIENT CHANNEL MEMBERS”; U.S. Patent Application Publication No. 2011/167742 A1 published Jul. 14, 2011 to James A. Klein assigned to Blazeframe Ind. Ltd. on “HEAD-OF-WALL FIREBLOCK SYSTEMS AND RELATED WALL ASSEMBLIES”; U.S. Pat. No. 7,681,365 B2 patented Mar. 23, 2010 to James A. Klein on “HEAD-OF-WALL FIREBLOCK SYSTEMS AND RELATED WALL ASSEMBLIES”; U.S. Pat. No. 7,814,718 B2 patented Oct. 19, 2010 to James A. Klein on “HEAD-OF-WALL FIREBLOCKS”; U.S. Pat. No. 7,866,108 B2 patented Jan. 11, 2011 to James A. Klein on “HEAD-OF-WALL FIREBLOCK SYSTEMS AND RELATED WALL ASSEMBLIES”; U.S. Pat. No. 8,056,293 B2 patented Nov. 15, 2011 to James A. Klein on “HEAD-OF-WALL FIREBLOCK SYSTEMS AND RELATED WALL ASSEMBLIES”; U.S. Pat. No. 8,136,314 B2 patented Mar. 20, 2012 to James A. Klein on “HEAD-OF-WALL FIREBLOCKS”; U.S. Pat. No. 8,151,526 B2 patented Apr. 10, 2012 to James A. Klein on “HEAD-OF-WALL FIREBLOCK SYSTEMS AND RELATED WALL ASSEMBLIES”; U.S. Patent Application Publication No. 2012/0297710 A1 published Nov. 29, 2012 to James A. Klein on “CONTROL JOINT BACKER AND SUPPORT MEMBER ASSOCIATED WITH STRUCTURAL ASSEMBLIES”; U.S. Patent Application Publication No. 2011/0099928 A1 published May 05, 2011 to James A. Klein and Alastair Malcolm on “DEFELCTION AND DRIFT STRUCTURAL WALL ASSEMBLIES”; CA Patent Application Publication No. 2550201 A1 published Dec. 15, 2007 to James A. Klein on “HEAD-OF-WALL FIREBLOCKS AND RELATED WALL ASSEMBLIES”; U.S. Pat. No. 8,181,404 B2 patented May 22, 2012 to James A. Klein on “HEAD-OF-WALL FIREBLOCKS AND RELATED WALL ASSEMBLIES”; U.S. Patent Application Publication No. 2013/0186020 A1 published Jul. 25, 2013 to Don A. Pilz assigned to California Expanded Metal Products Company on a “FIRE-RATED JOINT SYSTEM”; U.S. Pat. No. 8,353,139 B2 patented Jan. 15, 2013 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “WALL GAP FIRE BLOCK DEVICE, SYSTEM AND METHOD”; U.S. Patent Application Publication No. 2013/118102 A1 published May 19, 2011 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “WALL GAP FIRE BLOCK DEVICE; SYSTEM AND METHOD”; U.S. Patent Application Publication No. 2013/205694 A1 published Aug. 15, 2013 to James P. Stahl assigned to Specified Technologies Inc. on “INSULATING GASKET CONSTRUCTION FOR HEAD-OF-WALL JOINTS”; U.S. Pat. No. 8,375,666 B2 patented Feb. 19, 2013 to James P. Stahl et al assigned to Specified Technologies Inc. on “FIRESTOPPING SEALING MENAS FOR USE WITH GYPSUM WALLBOARD IN HEAD-OF-WALL CONSTRUCTION”; U.S. Patent Application Publication No. 2013/091790 A1 published Apr. 18, 2013 to James P. Stahl et al. assigned to Specified Technologies Inc. on “FIRESTOPPING MEANS FOR USE WITH GYPSUM WALLBOARD IN HEAD-OF-WALL CONSTRUCTION”; U.S. Pat. No. 7,240,905 B2 patented Jul. 10, 2007 to James P. Stahl on “METHOD AND APPARATUS FOR SEALING A JOINT GAP BETWEEN TWO INDEPENDENTLY MOVABLE STRUCTURAL SUBSTRATES”; U.S. Pat. No. 6,698,146 B2 patented Mar. 2, 2004 to Michael D. Morgan et al. assigned to W.R. Grace & Co.-Conn. on “IN SITU MOLDED THERMAL BARRIERS”; U.S. Pat. No. 6,783,345 B2 patented Aug. 31, 2004 to Michael D. Morgan et al. assigned to W.R. Grace & Co.-Conn. on “IN SITU MOLDED THERMAL BARRIERS”; U.S. Pat. No. 7,043,880 B2 patented May 16, 2006 to Michael D. Morgan et al. assigned to W.R. Grace & Co.-Conn. on “IN SITU MOLDED THERMAL BARRIERS”; U.S. Pat. No. 7,152,385 B2 patented Dec. 26, 2006 to Michael D. Morgan et al. assigned to W.R. Grace & Co.-Conn. on “IN SITU MOLDED THERMAL BARRIERS”; U.S. Pat. No. 5,010,702 patented Apr. 30, 1991 to T. L. Daw et al and assigned to Daw Technologies, Inc. on a “Modular Wall System”; and U.S. Pat. No. 5,127,203 patented Jul. 7, 1992 to R. F. Paquette on a “Seismic/Fire Resistant Wall Structure and Method”; and U.S. Pat. No. 5,755,066 patented May 26, 1998 to D. W. Becker on a “Slip Track Assembly; and U.S. Pat. No. 5,913,788 patented Jun. 22, 1999 to T. R. Herren on a “Fire Blocking And Seismic Resistant Wall Structure”; and U.S. Pat. No. 5,921,041 patented Jul. 13, 1999 to J. D. Egri, II on a “Bottom Track For Wall Assembly”; and U.S. Pat. No. 5,950,385 patented Sep. 14, 1999 to T. R. Herren on an “Interior Shaft Wall Construction”; and U.S. Pat. No. 6,058,668 patented May 9, 2000 to T. R. Herren on a “Seismic And Fire-Resistant Head-of-Wall Structure”; and U.S. Pat. No. 6,176,053 patented Jan. 23, 2001 to Roger C. A. St. Germain and assigned to Robert C. A. St. Germain on a “Wall Track Assembly And Method For Installing The Same”.

Although the known fire block header tracks provide exceptional performance, there still exists a need for fire block arrangements that can be applied to any desired structure, such as the wall, floor or ceiling of a building construction or to the stud wall assembly and to header tracks. Furthermore, as described herein, alternative embodiments of the wall gap fire blocks can be applied to a wall bottom track to protect a foot-of-wall gap or a (vertical or horizontal) gap in a location other than the head or foot of a wall. The present fire blocks are well-suited to application on the job site.

In brief, the present invention in one embodiment is directed in general to a fire retardant head-of-wall assembly configured to seal a linear head-of-wall or similar construction joint or gap when exposed to a heat source, such as in the event of fire. In more detail the present invention is directed to a firestopping sealing for use with dry wallboard, i.e., gypsum wallboard, in a head-of-wall or similar construction including an insulating strip, in particular an elongated insulating material strip, and optionally a cover layer. The insulating strip being positioned on at least one portion of the leg of the track, whereas the insulating material strip only in some embodiments will be affixed on the leg of the track. The insulating material strip having an outer strip surface offset from the outer leg surface an insulating material strip offset distance and an inner strip surface directed towards the leg surface. In other words, one strip surface faces away from the leg surface towards the wallboard and the other strip surface is directed towards the leg surface.

In some embodiments the strip surface which is directed towards the leg surface comes in direct contact with the leg surface.

In some embodiments no adhesive power acts between the strip and the leg. In other embodiments an adhesive power acts between the strip and the leg, in particular when the insulating material strip consists of a sticky material and therefore provides stickiness by itself, or alternatively, when an additional adhesive layer is provided on the strip.

Preferred embodiments of the present invention provide an optional adhesive insulating material strip that can be applied to a header track or other head-of-wall structure to create a head-of-wall insulation block, in particular fire block. The adhesive insulation strip may provide adhesion by itself, i.e., by the material the insulation material is made of, or by providing the insulating material with an adhesive.

In one embodiment the insulating strip comprises an insulating material strip and a cover layer that covers the insulating material strip whereas the cover layer secures the insulating strip to the (concrete) construction element, such as a wall, floor or ceiling (also referred to as overhead structure).

The insulating material strip may include non-intumescent and/or intumescent materials, but will preferably include intumescent materials to provide enhanced sealing in the event of fire. These intumescent materials may be constructed partially or entirely from an intumescent material such as CP 646 from Hilti, for example. It is also possible for the insulating material of the present invention to have components of both intumescent and acoustical sealing therewithin. It is particularly preferred that the insulating material includes an intumescent material only. The acoustical insulating material is intended for applications where sealing against sound transmissions is found to be desirable in addition to firestop. Such acoustical insulating configurations can preferably be formed of a felt acoustical insulating material. Alternatively, it can be formed of a foamed insulating material which can easily be provided with intumescent properties by including intumescent additives.

When the temperature rises the intumescent material will expand quickly and block air pathways. In this manner, the entire gap or joint between the construction element and the top of the drywall assembly, in particular the wallboard and/or track, will be sealed, substantially preventing fire, heat, and smoke from reaching other rooms or parts of the building for at least some period of time.

The insulating material may preferably be constructed partially or entirely from a pressure-resistant material such as acrylate based polymer or a hard putty such as rubber, e.g., polyisobutylene based rubber. These materials may include a reinforcing member such as glass fibers or a glass fiber fabric to enhance strength of the material. The term “pressure-resistant” means that while installing the wallboard, the material shall be deformed only slightly so that in case of vertical movement of the wallboard tilting and entanglement of the insulating material are always avoided.

In another embodiment the insulating material may be constructed partially or entirely from a compressible material such as plasticines, fabric (non-woven or woven) or a felt, e.g., glass fiber braid, glass fiber fabric or glass fiber mat. Plasticines, which are also referred to as putties, are frequently used for this application. They generally consist of a liquid polymer such as butyl rubber, plasticizers (paraffin oil, phthalates, adipates, etc.) and fillers, with a filler content of up to 80 percent. In particular the plasticine contains, as liquid polymer, at least one representative of the group comprising polyurethanes, polyvinyl acetates, polyvinyl ethers, polyvinyl propionates, polystyrenes, natural or synthetic rubbers, poly((meth)acrylates) and homopolymers and copolymers based on (meth)acrylates, acrylonitrile, vinyl esters, vinyl ethers, vinyl chloride and/or styrene, preferably poly(alkyl methacrylate), poly(alkyl acrylate), poly(aryl methacrylate), poly(aryl acrylate) and/or copolymers thereof with n-butyl acrylate and/or styrene. The plasticine may include fire-protection additives. In this regard reference is made to the U.S. patent application No. 2005/032934 A1 which is incorporated in its entirety herein by reference.

More preferably the insulating material is also abrasive-resistant to resist abrasion caused by the wall member rubbing against the insulating material when moving up and down to due movement of the building.

If sound insulation is desired without using an additional sound proofing material, the insulating material is made of a material that provides both firestopping, in particular intumescent properties, as well as sound or acoustic insulation properties, e.g., plasticines or foams having intumescent properties.

Intumescent materials include standard fire protection additives known to a person skilled in the art which foam in the event of fire, i.e., with exposure to heat, and in doing so form a foam that inhibits flame propagation, such as an intumescent material based on an acidifier, a compound supplying a carbon and a gas former. The intumescent material preferably includes, as the acidifier, a salt or ester of an inorganic non-volatile acid selected from sulfuric acid, phosphoric acid, and boric acid; as the compound supplying carbon, a polyhydroxy compound and/or a thermoplastic or thermosetting polymer resin binding agent; and as the gas former, a chlorinated paraffin, melamine, a melamine compound, in particular melamine cyanurate, melamine phosphate, melamine polyphosphate, tris(hydroxyethyl)-cyanurate, cyanamide, dicyanamide, dicyandiamide, biguanidine and/or a guanidine salt, in particular guaninide phosphate or guanidine sulfate.

The insulating material strip also includes a cover layer. The cover layer has two main functions. On the one hand it enables mounting the insulating material strip on the wall or ceiling. On the other hand it provides sufficient sealing of the joint or gap between the dry wall assembly, in particular header track or bottom (floor) track, and the construction element, i.e., wall, floor or ceiling. A further function depending on the material used for the insulating material strip is to provide abrasive-resistance to the insulating material strip.

Therefore, the cover layer is made of an airtight material. Preferably, the cover layer is made of both an airtight and an abrasion-resistant material to provide a sealing against cold gases, like smoke or other harmful gases, and to provide resistance against abrasion resulting in loss of the insulating material caused by repeatedly rubbing of the wallboard over the insulating material. The cover layer can be a film material, preferably a synthetic film like plastic or poly-type material such as polyvinyl chloride or polyalkylene material, for example polyethylene material. Alternatively the cover layer can be an inorganic material, like metal films or any other suitable material. The cover layer provides protection in the event that the wall is designed to accommodate vertical movement, which could result in the wallboard rubbing against the insulating material. However, the cover layer still permits the insulating material to expand in case it includes an intumescent material. In one embodiment the cover layer has a printable surface.

The cover layer in one embodiment is abrasive-resistant to resist abrasion caused by the wall member rubbing against the insulating material when moving up and down due to movement of the building. This is particularly important in case the insulating material will not follow the movement of the wall member and will maintain its position towards the header track, especially when an adhesive power acts between the insulating material strip and the leg of the header track.

In another embodiment the surface properties of the cover layer are such that the cover layer adheres to the wall member and will follow the movement of the wall member and moves up and down due to movement of the building. In this case the insulating material strip will move relative to the header track. In this embodiment the insulating material shall be provided with sufficient abrasion resistance towards the header track either by being abrasive-resistant by itself or by being provided with an additional abrasive-resistant cover layer. Abrasion resistance or enhanced abrasion resistance of the insulating material can be provided by including a cover layer on one side (surface) of the insulating material. This is important in particular when the insulating material strip itself is made from a soft and more or less compressible material. However, a hard and/or pressure-resistant material is also provided with a cover layer.

After the insulating material is being brought into its desired positioned near the track, the cover layer will constitute the outer surface of the material. The cover layer will come into contact with the wallboard or similar construction element. The side portion of the cover layer with which the insulating material strip is fixed on the construction element will then point away from the track.

In each of the various embodiments the cover layer includes at least one side portion that extends outwardly from the insulating material strip and therefore has a greater dimension than the insulating material. The dimension of the cover layer shall be selected such that sufficient adhesion to the construction element, like a wall, floor or ceiling, can be achieved by the side portion. But, for improved appearance the insulating material strip, in particular the cover layer, shall not extend beyond the joint, i.e., when mounted on the construction element, e.g., ceiling, the cover layer shall not extend beyond the wallboard member and thus shall not be visible after the wallboard member is mounted. Moreover, the cover layer must not affect movement of the wallboard member. Thus, the cover layer shall be as thin as possible.

In another embodiment, the cover layer includes two side portions that extend outwardly from the insulating material strip, i.e., the cover layer covers the insulating material strip and also extends to each side thereof. With one side portion the intumescent material strip will be fixed to the leg of the track and with the second side portion the intumescent material strip will be fixed to the construction element, such as a wall, floor or ceiling. This assures that the insulating material strip stays in places during up and down movement of the wallboard.

The dimensions of the insulating material shall be selected such that the wallboard member anytime contacts the insulating material strip to ensure sufficient airtightness. The thickness of the insulating material shall be selected such that in case the insulating material strip is used with slotted tracks the screw heads fit between the header track and the wallboard member and do not cause damage to the insulating material strip in case of movements.

In a preferred embodiment the insulating material strip is an elongated strip to be positioned lengthwise at the leg of the header track such that the insulating strip has a great length in one direction and a smaller width to cover only part of the leg of the track. Preferably, the insulating strip is designed as an endless strip. The cover layer then shows a greater width than the insulating material. The insulating material is positioned on the cover layer such that both are aligned at one edge (i.e., have a joint edge) and the cover layer only extends beyond one side.

The insulating material strip is adapted to extend along a length of the track having a first surface and a second surface. The first surface faces the track and the second surface faces and contacts the wallboard, where each surface defines a length and a width. The width is less than the width of the leg of the track to not cover the leg entirely. With this, the insulating material strip can be positioned on the leg of the track such that the insulating material portion of the strip is positioned either in a middle part, an upper part or a bottom part of the leg. Preferably, the insulation material strip is positioned on the leg such that the insulating material portion thereof is positioned in the middle or more preferably upper part of the leg.

The underneath surface of the cover layer includes an adhesive or adhesive layer (herein both referred to as adhesive). The adhesive has two functions. On the one hand the adhesive is to affix the insulating material to the cover layer. On the other hand, the adhesive is to affix the insulating material strip to the wall, floor or ceiling of the construction. The adhesive must provide sufficient adhesion to construction elements made of various materials, like concrete, brick, wood and the like. Suitable adhesives are, for example, acrylic adhesives, butyl rubber adhesives, and bitumen.

Preferably a removable protective layer covers that part of the underneath surface of the cover layer which extends beyond the insulating material until the insulating strip is ready to be applied.

In case the insulating strip follows the up and down movement of the wallboard the at least one side portion of the cover layer that extends beyond the insulating material strip must have a sufficient width or is partly detachably fixed to the construction element, like a wall, floor or ceiling to enable movement of the insulating material strip. The partial detachable fixation could be made by using an adhesive layer that is highly adhesive (almost permanent) on one part of the side portion, namely the outer part, and mildly adhesive on the other, namely the part abutting the highly adhesive and the insulating material strip. Alternatively, the cover layer is durably fixed to the construction element, like a wall, floor or ceiling, the material of the cover layer shall provide sufficient elasticity to enable movement of the insulating material strip without the side portion of the cover layer being detached from the construction element.

In case the insulating material strip is not fixed on the track, in particular the leg, by an adhesive or the insulating material strip does not consist of a material that provides adhesion by itself the only fixing will be provided by the side portion of the cover layer that is attached to the construction element. In the event of fire it could happen that the cover layer does not provide sufficient stability to keep the intumescent in the desired position that is near the gap or joint between the track or the wallboard and the construction element. As a result the insulating material strip will slide downwards away from the gap or joint. Moreover, the cover layer may impede the intumescence of the insulating material strip and the expanded material does not reach into the space before the gap or joint between the track and the construction element or does not fill the space between the wallboard and the construction element.

To deal with this, the present invention also provides a second embodiment of an insulating strip.

The insulating strip includes an insulating material strip and optionally a cover layer. The insulating material strip is either self-adhesive due to its material or is provided with an adhesive layer. The materials of the insulating material strip and the material of the optional cover layer as well as the adhesive are the same as described above for the first aspect.

The insulating strip is directly mounted on the construction element just before the track, i.e., in direct abutment with the leg of the track to extend along the leg. Optionally the insulating material strip can additionally be fixed on the leg.

With this embodiment it is assured that sufficient insulating material will always be positioned directly before the gap or joint between the top of the track (web) and the construction element to seal the gap or joint against sound, smoke, cold gases and hot cases and fire.

One advantage of this aspect is that no intumescent material will be needed to achieve sufficient firestopping properties. For enhanced firestopping properties it is, however, preferred that the insulating material has intumescent properties. It is also possible that the insulating material strip includes a portion having non-intumescent properties and a portion having intumescent properties. For such an arrangement, it is preferred that the non-intumescent portion of the strip is positioned directly before the gap or joint between the top of the track and the construction element. The intumescent portion of the insulating material strip may then be positioned on the leg.

When an intumescent material is used, the intumescent material will expand quickly and block all air pathways when the temperature rises. In this manner, the entire gap or joint between the construction element, such as a wall, floor or ceiling and the track, and also the gap or joint between the construction element and the wallboard will be sealed, substantially preventing fire, heat, and smoke from reaching other rooms or parts of the building for at least some period of time. Since in this embodiment no cover layer is used, the insulating material can expand freely into the gaps or joints when the temperature rises.

In one embodiment the insulating material strip includes two portions, one main portion and an angled side portion constituting an L shaped strip. The side portion can be connected in one piece with the main portion, whereas the main portion will be positioned along the leg of the track and the side portion will be directed away from the track. The side portion constitutes that part of the insulating strip with which the strip is attached to the construction element.

Since the gap or joint between the track and the construction element in general will be very small, the thickness of the side portion may also be very small. For some application it will be sufficient, if only the main portion is made of an intumescent material. The side portion then can be made of a material that forms a stable ash crust when exposed to heat as in the event of fire. This material can be the same as the material of the main portion, however, without being provided with intumescent properties.

Optionally the insulating strip can include a cover layer to provide abrasion resistance to the insulating strip and to ensure or facilitate movement of the wallboard. The cover layer will be used depending on the material used for the insulating material strip as described above for the first aspect.

In another embodiment the insulating strip includes an insulating material strip and a cover layer, whereas the insulating material strip is a two-part strip having a first (main) portion and a second (side) portion separated from each other. The first and the second portion are connected to one another by a cover layer.

In this embodiment, the first (main) portion of the insulating material strip will be positioned along the leg of the track, preferably on the lower part of the leg. The second (side) portion will be positioned on the construction element near the track, i.e., in direct abutment with the track, to seal the gap or joint between the wallboard or track and the construction element.

This embodiment is particularly designed to be used with slotted tracks but may also be used with solid tracks. When used with slotted tracks the first portion of the insulating material strip will be positioned in the lower part of the leg below the screws for fixing the wallboard. The second portion of the insulating material strip will be positioned on the construction element near the track, i.e., in direct abutment with the track, to seal the gap or joint between the wallboard or track and the construction element.

The optional cover layer provides a sealing against cold gases and seals the slots of the track until the insulating material sufficiently expands.

Since the gap or joint between the track and the construction element in general will be very small, the thickness of the second (side) portion may also be very small. For some application it will be sufficient, if only the first (main) portion is made of an intumescent material. The second (side) portion then can be made of a material that forms a stable ash crust when exposed to heat. This material can be the same as the material of the first (main) portion, however, without being provided with intumescent properties. It is preferred that the material of the second (side) portion of the material strip is a material that additionally provides sound and acoustic insulation, such as a compressible material.

The above-described and other features, aspects and advantages of the present invention are described below with reference to drawings of preferred embodiments, which are intended to illustrate, but not to limit, the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a is a cross-sectional view of a portion of a stud wall assembly with an insulating strip assembly installed at the head-of-wall according to one embodiment of the first aspect of the invention;

FIG. 1 b is a cross-sectional view of a portion of a stud wall assembly with an insulating strip assembly installed at the head-of-wall according to the embodiment of the first aspect of the invention after movement of the stud wall assembly shown in FIG. 1 a;

FIG. 2 a is a cross-sectional view of a portion of a stud wall assembly with the insulating strip assembly installed at the head-of-wall according to another embodiment of the first aspect of the invention;

FIG. 2 b is a cross-sectional view of a portion of a stud wall assembly with an insulating strip assembly installed at the head-of-wall according to the another embodiment of the first aspect of the invention after movement of the stud wall assembly shown in FIG. 2 a;

FIG. 3 is a cross-sectional view of a portion of a stud wall assembly with an insulating strip assembly installed at the head-of-wall according to a further embodiment of the first aspect of the invention;

FIG. 4 a is a cross-sectional view of an embodiment of the insulating strip assembly according to one embodiment of the second aspect of the invention having certain features, aspects and advantages of the present invention;

FIG. 4 is a cross-sectional view of a portion of a stud wall assembly with the insulating strip assembly of FIG. 4 a;

FIG. 5 a is a cross-sectional view of an embodiment of the insulating strip assembly according to another embodiment of the second aspect of the invention having certain features, aspects and advantages of the present invention; and

FIG. 5 is a cross-sectional view of a portion of a stud wall assembly with the insulating strip assembly of FIG. 5 a.

DETAILED DESCRIPTION OF DRAWINGS

As shown in FIG. la an insulating strip 1 includes an insulating material strip and a cover layer is affixed on the support structure, e.g., overhead structure, with the portion of the cover layer extending beyond the insulating material strip. The insulating material strip is positioned lengthwise in abutment with at least one, preferably both legs 9 of the header track 7, and preferably comes in contact therewith. The insulating strip 1 is positioned so that its top edge provides for enhanced sound and smoke containment especially in cases of an uneven or spawled horizontal support structure surface. The cover layer supports movement of the wallboard 11 and protects the insulating material strip against abrasion due to the movement of the wallboard 11. The insulating material strip can be additionally attached to the leg 9 either by an adhesive (not shown) or by using a self-adhesive material as insulating material. Thus, the insulating strip will stay in place and will not follow the movement of the wallboard 11 as best shown in FIG. 1 b. The arrows indicate downwards movement of the wallboard 11, whereas the track 7 and the insulating strip 1 won't move.

As shown in FIG. 2 a an insulating strip 1 includes an insulating material strip and a cover layer is affixed on the support structure, e.g., overhead structure, with the portion of the cover layer extending beyond the insulating material strip in the same manner as shown in FIG. 1 a. In the embodiment shown, the insulating strip 1 differs from the one shown in FIGS. 1 a and 1 b in that it enables movement of the insulating material strip such that the insulating material strip moves when the wallboard moves as best shown in FIG. 2 b. This difference (not shown) is either enabled by the material of the cover layer and/or by the material of the insulating material strip and by omitting an adhesive layer between the insulating material strip and the leg 9. The arrows in FIG. 2 b indicate downwards movement of the wallboard 11 and the insulating material strip, whereas the track 7 and the second portion of the insulating strip will at least partially be adhered to the support structure 10.

FIG. 3 illustrates another embodiment of the insulating strip 1 of the first aspect of the invention applied to a head-of-wall structure, which is similar to the insulating strip 1 of FIGS. 1 a and 2 a, except that the cover layer includes a further side portion. Accordingly, the same reference numbers are used to indicate the same or similar components or features between the two embodiments. With reference to FIG. 3 the insulating strip 1 is positioned on the leg 9 of the header track 7 between the header track 7 and the wallboard 11. The cover layer covers the insulating material strip and also extends to each side. The cover layer secures the insulating strip 1 to both the support structure 10 and the leg 9 of the header track 7.

With reference to FIGS. 1 a, 2 a and 3, although two insulating strips 1 are shown on both sides of the header track 7 only one insulating strip 1 may be positioned on one side of the header track 7.

FIGS. 4 a and 5 a illustrate various types of an elongated insulating strip assembly 1, which is also referred to herein as an insulating strip, according to preferred embodiments of the second aspect of the invention.

FIGS. 4 and 4 a illustrate an elongated insulating strip assembly 1 according to one embodiment of the second aspect of the invention. The insulating strip 1 is an elongated strip assembly that preferably is constructed as an integrated assembly of multiple components. The insulating strip 1 may be supplied on a roll, in a folded arrangement or any other suitable manner. Preferably, the insulating strip 1 is provided as a separate component that is applied to a head-of-wall in the field, as is described in greater detail below.

The illustrated insulating strip 1 includes an insulating material strip 20. The insulating material strip 20 includes a first (main) portion 21 and a second (side) portion 22. An optional cover layer 23 covers the insulating material strip 20. The cover layer 23 covers only the insulating material strip 20. In such an arrangement, the insulating strip 1 may be secured to a construction product by an adhesive (not shown) applied to the bottom of the insulating material strip 20 or by the insulating material strip itself, if the strip consists of a self-adhesive material. An additional adhesive may be applied to the upper face of the insulating material strip 20 to secure the insulating material strip 20 to the cover layer 23, if the latter is used.

The insulating material strip portion 22 may be constructed from putty that may additionally contain intumescent additives, which however will not be necessary to provide sufficient insulation for sound, cold gases, smoke, and firestop. The insulating material strip portion 21 is preferably constructed from a material that has intumescent properties. More preferably, this material is pressure resistant and abrasive-resistant on its own. And still more preferably, this material also has intumescent properties.

FIGS. 5 and 5 a illustrate an elongated insulating strip assembly 1 according to another embodiment of the second aspect of the invention. The insulating strip 1 is an elongate strip assembly that preferably is constructed as an integrated assembly of multiple components. The insulating strip 1 may be supplied on a roll, in a folded arrangement or any other suitable manner. Preferably, the insulating strip 1 is provided as a separate component that is applied to a head-of-wall in the field, as is described in greater detail below.

The illustrated insulating strip 1 includes two intumescent material strip portions 21 and 22, the first (main) portion 21 and the second (side) portion 22. A cover layer 23 covers and connects the first (main) portion 21 and the second (side) portion 22. In such an arrangement, the insulating strip 1 may be secured to a construction product by an adhesive (not shown) applied to the bottom of the insulating material strip portions 21 and 22 or by the insulating material strip itself, if the strip consists of a self-adhesive material. An additional adhesive may be applied to each upper face of the insulating material strip portions 21 and 22 to secure the portions to the cover layer 23.

The insulating material strip 20 may be constructed from putty that may additionally contain intumescent additives. For this embodiment the insulating material preferably is made from an intumescent material.

The cover layer provides protection in the event that the wall is designed to accommodate vertical deflection, which could result in the wallboard rubbing against the insulating material, leading to loss of insulating material, for example. In addition, the cover layer includes an adhesive layer (not shown) on the underneath side that faces the insulating material strip 20 and protective layer. Thus, in some arrangements, the cover layer 23 is a tape, such as a polypropylene tape, also referred to herein as poly tape. Other suitable tapes may also be used. The cover layer 23 may be clear or somewhat clear so that the insulating material strip 20 is visible through the cover layer 23 to ease assembly onto a header track or other head-of-wall structure.

FIG. 5 illustrates the insulating strip 1 of FIG. 5 a applied to a head-of-wall structure including a header track 7 with a web 8 and legs 9 extending downwardly from the web at opposite sides of the track and a plurality of studs (not shown). As shown in FIG. 5 the insulating strip 1 of FIG. 5 a shows a first insulating material strip portion 21, which is affixed lengthwise on the leg so that the portion 21 comes in direct abutment with the lower edge of the leg 9. The second insulating material strip portion 22, which is fixed directly on the support structure, e.g., ceiling, is directed away from the track 7 to be positioned in the gap between the wallboard 11 and the support structure, e.g., overhead structure 10, and covers the gap or joint between the top surface of the web 8 and the overhead structure. The cover layer 23 provides a barrier for cold gases and smoke.

While particular embodiments of this invention have been shown in the drawings and described above, it will be apparent that many changes may be made in the form, arrangement and positioning of the various elements of the combination. In consideration thereof, it should be understood that preferred embodiments of this invention disclosed herein are intended to be illustrative only and not intended to limit the scope of the invention.

The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be constructed to include everything within the scope of the appended claims and equivalents thereof. 

What is claimed is:
 1. A sealing element for sealing a gap between a support structure and a track, wherein the track includes a web and legs that extend vertically from the web, comprising: an insulating strip including an insulating material strip and a cover layer; wherein the cover layer has a first portion that extends beyond the insulating material strip and wherein the first portion is adhesively attached to the support structure; wherein the cover layer has a second portion with a first face adhesively attached to a first face of the insulating material strip and a second face that abuts a wallboard; and wherein a second face of the insulating material strip abuts a leg of the track.
 2. The sealing element according to claim 1, wherein the second face of the cover layer is not adhesively attached to the wallboard.
 3. The sealing element according to claim 1, wherein the second face of the insulating material strip is adhesively attached to the leg.
 4. The sealing element according to claim 1, wherein the second face of the cover layer is adhesively attached to the wallboard.
 5. The sealing element according to claim 1, wherein the second face of the insulating material strip is not adhesively attached to the leg.
 6. The sealing element according to claim 1, wherein the cover layer includes a third portion, wherein the third portion includes a first section that covers a bottom face of the insulating material strip and a second section that abuts the leg.
 7. The sealing element according to claim 6, wherein the second section is adhesively attached to the leg.
 8. A sealing element for sealing a gap between a support structure and a track, wherein the track includes a web and legs that extend vertically from the web, comprising: an insulating strip including an insulating material strip, wherein the insulating material strip includes a first portion and a second portion and wherein the first portion and the second portion form an L-shape; wherein the first portion is disposed along a leg of the track and wherein the second portion is adhesively attached to the support structure.
 9. The sealing element according to claim 8, wherein the second portion extends in a direction facing away from the leg.
 10. The sealing element according to claim 8, wherein the insulating strip further includes a cover layer disposed on a side of the insulating material strip that faces away from the support structure and the leg.
 11. A sealing element for sealing a gap between a support structure and a track, wherein the track includes a web and legs that extend vertically from the web, comprising: an insulating strip including an insulating material strip and a cover layer, wherein the insulating material strip includes a first portion and a second portion, wherein a gap is disposed between the first portion and the second portion, and wherein the cover layer is attached to the first portion and to the second portion; wherein the first portion is disposed along a leg of the track and wherein the second portion is adhesively attached to the support structure.
 12. The sealing element according to claim 11, wherein the second portion extends in a direction facing away from the leg.
 13. The sealing element according to claim 11, wherein the cover layer is a tape.
 14. The sealing element according to claim 11, wherein the cover layer is disposed on respective sides of the first portion and the second portion that face away from the leg and the support structure, respectively. 